Spaced panel wall structure



June 14, 1960 G. GASPAR SPACED PANEL WALL STRUCTURE Filed Jan. 14, 1957 INVENTOR LESTER e 'GASPER m w 0 a my Wu 0 Em N mm W ATTORNEYS United States Patent SPACED PANEL WALL STRUCTURE Lester G. Gaspar, 307' Hillside Ave, Richardson, Tex. Filed Jan. 14, 1957, Ser. No. 633,861

2 Claims. (Cl. 72-44) This invention relates to the field of construction, and particularly to devices for building structures such as Walls and the like, and methods incident thereto.

In standard construction procedures, form-work for structures such as concrete walls, beams, columns, partitions, and the like, is made of oil impregnated forms such as wooden panels which have to be assembled, erected, plumbed and secured at uniform distances with wire ties. Usually, the wire ties are secured at opposite ends to the wooden panels on each side of the Wall. For drawing the wooden panels together, the ties are twisted in any conventional manner.

After the concrete is'poured and sufficiently hardened, the wooden panels mustbe removed. To do this, the wire ties are cut on the outside of the panels. Consequently, after the panels are removed, portions of the wire ties protrude from the concrete and must be broken off. Any holes that are left by the broken off section of the wire ties are then patched with concrete. If the concrete is in a location which requires it to have a finished appearance, the surface must be rubbed, usually by hand, at a high cost.

As is apparent from the precedingparagraph, the conventional method of forming concrete walls and the like is wasteful of materials and of time, since the lumber used for forming the wall must be removed and generally has no place in a finished building. Also the conventional method requires multiple handling of most of the parts of the form especially when some of the parts may be reused as, for example, in the building of new forms for another wall. The continuous stripping of the forms and breaking ofi ties is highly objectionable from the standpoint of the great number of man-hours required. Additionally, storage of oil impregnated forms in a building, for example, constitutes a fire hazard, requiring extended fire protection.

Therefore, it is the principal object of this invention to provide for a construction panel which may become a permanent part of a structure in which it is used.

Another object of this invention is to provide a set of panels for forming a concrete wall, or the like, said panels being separated uniformly by a rod spaced therebetween and being locked to said rod respectively by keepers interconnecting loops extending from each of said panels.

Another object of this invention is the provision of a panel for use in constructing a wall of uniform thickness by a loop extending from the panel for locking the panel in a predetermined position.

Another object of this invention is the provision of a panel for use in construction of a wall, said panel having reinforcing means, a portion of which protrudes to form a loop for securing the panel in place.

I Another object of this invention is the provision of spacer means for'separating and holding the side panels of a wall at a uniform distance.

Another object of this invention in conjunction with the preceding object is the provision of catch means co- 2,940,296 Patented June 14, 1960 operating with said spacer means and with the panels of a wall whereby the panels may be locked into place.

Another object of this invention is the provision of a method for constructing a wall structure or the like including locking spacer means between two panels to the loop means extending from opposing faces of the panels.

Another object of this invention is the provision of a method for maintaining the prefabricated panels of a wall structure plumb.

Another object of this invention is the provision of improved apparatus for maintaining the prefabricated panels of a wall structure plumb.

Other objects of this invention will become apparentto those skilled in the art upon attaining a knowledge of this invention as exemplified in the subsequently described modifications and illustrations, and the appended claims. For purposes of illustration, an exemplary modification in accordance with the invention is shown in the drawings, wherein:

Figure l is a perspective view of the inward face of one side of a wall including four panels;

Figure 2 is an elevational view of a portion of a wall before being filled with concrete or the like;

Figure 3 is a catch usable with the apparatus illustrated in Figure'2;

Figure 4 illustrates plumbing a panel, and

Figure 5 is a strap for use in plumbing the panel in Figure 4.

Although the invention will be described in relation to the construction of a wall, any upright structure, Whether its sides are parallel or not, is intended to be encompassed by this invention. Also, limitation to a settable material such as concrete as being the material placed between the outside panels is not intended since other material including air may, if desired, be used there between for insulating or other purposes.

As is illustrated in Figure l, the wall to be built may consist of a number ofsections or panels 10, only four of which are shown. Such panels are preferably, without limitation intended, prefabricated out of concrete using a light weight aggregate and are comparatively light in weight. The outer face 12 of the different panels is made flush by the edge liners 14 which extend from the side edges of each panel to receive an adjacent panel;

In accordance with thisinvention, each panel may have reinforcement means pre-formed within a panel in the configuration of wire mesh or rods extending longitudinally of the panels. At predetermined points along the inside surface 16 of the panels, the wire mesh or reinforcement means protrudes to form tie means such as loops 18. This is perhaps better seen in Figure 2 where the reinforcement wire or red 20 extends in a V-shaped manner beyond the inner face 16 of the panel 10.

Each edge liner 14 as shown in Figure 2 extends along the inner surface 16 of the panel 10 a short distance, thence inwardly and then further at right angles along the length of the panel for securing the edge liner permanently within the panel. It will be understood that the edge liners 14 and the reinforcing wires or rods 20 are pro-formed and secured within the panel 19 by the hardening of the concrete of which panels 16 are composed.

Referring further to Figure 2 and to panel 22 which opposes panel 1%, it will be apparent that the two panels are. similarly constructed each with an edge liner 14. Reinforcement wire or rod 24 extends inwardly as a loop 26. The outer surfaces 12 and 28 of both panels may be finished as desired, while the inner surfaces 16 and 30 can be left unfinished or with a broom finish.

In order that neither of the two opposing panels 10 and 22 collapse or bulge under forces of poured concrete,

- a spacer 32 is provided to fixedly separate the panels a -material filling in the space between the panels.

predetermined distance. Spacer 32 has formed at both 1 ends thereof buttons or heads 34 and 36. However, before the forming of heads 36, two catches such as clips 38 and 40. are placed on the. spacer rod 32; r

Theiclips' 38 'and 40. may beidenticaland Figure illustrates one suchclip before being bent and placed on the'spacer. rod 32. 1 In Figure 3; the clip is shown 'blankedout or as otherwise cut originally to form one (formed because of slit 49) extending against a panel 1;

while theisurface having the aperture 46 abuts against the inner or underside of the head 34 and 36 of the spacer rod 32. The, clip also has two semi-circular, cut-away portions 56Iand 52 on each of thetwo lower sloping or beveled sides 54. When the ,clips'a'rebent and in place on the spacer rod 32, the cut-away portions 50, 52, coin cide at least in part with a loop such as the bottom of the V-portion of loop 18 orthe loop 26. "When such is the case, the spacer rod and panels may be locked inplace by a keeper such'as rods 56 and 58 extending through and seated in the cut-away portions or seats 50 and 52 which coincidewith-the bottom of the V partof loops 18 and 26 respectively; The rods 56 and 58 also extend to at least one'other loop. along a row of such loops to securely hold the spacer rod and clip means in position. 7 Because of thesloping or beveled lower edges 54 of eachof clips' 38 and 40, the assembly of a wall may be shaped. Also, inven on. encompasses the use of loops 18 and 26. For example, the loop means extending from the panel could be a single wire secured to or wrapped, for example, around the reinforcing rod or wire mesh 20 with a hook or. a fully closed loop at its opposite end for receiving akeeping rod. Of course, the reinforcement fneanswithin thepanels need not be utilized. and whether or not such is within the panels, the loop means may be secured in any desired manner externally on the inside surface of a panel. j v

The clips 38 and 40 need not be used as'long' as some means is provided for securing or for preventing lateral movement of the panels. For example, the heads of the spacer rod 32 could have their, inner side cut away so as to'serve thesame purpose as do the cut-away portions 50, 52 oftheclips. In that ,manner the'clips would .not

expedited by depressing the spacer rods and thin clips into position while the longitudinally extending rods 56 I and 158 are disposed in their respectiverrows of loops From the foregoing it is apparent that concrete or any other material may be placed between panels 10 and 22 without the panels buckling. or bulging, and that there need be no subsequentremoval of the panels. Consequently, no tie wire ends arefexposed and no patching need be done. The panels 10 and 22 are preferably of concrete and may be pre-formed in the color and texture desired so as to yield, a more uniform result, especially when the pro-forming is done in a manufacturing plant. M

j The thickness of concrete panels may ,vary as required 7 by a particular use contemplated therefor. 7 Without any limitation intended,a panel may be 1 /2 inch% thick and 4 feet wide by 8 feet long. Such'a concrete panel is light weight and can be convenientlyrcut on location to permit fitting panels into tight places and for openings and beams and the like.

' The clips 33 and 40 are preferably made of sheet metal 7 and of a gauge sufficient to withstand the stress placed upon the clips and punching out'the shape of the clips can be conveniently done by modern;presses with ease. The rods 56 and 58 must be strong enough to withstand the outward forces exerted by the concrete or other Prefer: ably, these rods run at least the full length of one panel.

be essentials} I Fromvthe foregoing, it be apparent? thatitlieapparatus provided'may form awall with a'finished .face and stripping, patching and rubbingare clearly reduced if not completely. eliminated. No tiesor the like. will protrude and no breaking is necessary.v The concrete poured in this form is permanently protected for cnring, and the normal amountofhoneycombing withthe structure does not expose the steel to ;rust, because the form (i.e., the

, panels) can be;cast or; otherwise formed to: have no honeycomb.

j Although a wa'lllconstructedin the. manner. described above will, in and of itself, bestrong enoughrso as to maintaina plumb position, it may be desirabletto' pro- '2 wide additional apparatus to plumb the panels on one side of thewall, before connecting the panels on the opposite side ofthe wall thereto, Apparatus for accom plishing plumbing is illustrated in Figures 4 and 5. vWith reference to Figure 4, it will be appreciated that panel 70 may belike any one of the panels 10 in Figures 1' and 2, or may be any other type of prefabricated panel. To maintain a panel plumb, members 72 and 74, such as wooden 2 x 45, are made plumb and, held insuchposition in any conventional manner. Along the side of plumb members 72 and 74, which is not in contact with panel 70, thereis disposeda transverse member 76 in a direction substantiallytransyerse to plumb members 72 and. 74. In ordertomaintain the panel 70 against the plumb members 72, 7 4, hooking means are utilized. The hooking'means in the specific embodiment illustrated, include member 76, which may be; another wooden-2 x 4. Also included in the hooking means are straps 78 and 80 and'edge liner 82, the edgeliner for strap 80 not being visible. The straps 78 and 80 may be originally in the form illustrated in Figure 5 with an aperture 84 in one Besides accomplishing a keeper. or locking purpose, rods 56; and 58 provide'reinforcement means for concrete poured between the two panels.

Even though the loops ,18' and 26 are shownjtobe V-shaped, it is apparent that they could as well-lua end portion thereof for receipt of the edge liner 82. The strap also;has notches 86 a1ong the edges thereof and slightly inward from the aperture 84. Additionally, numerous other apertures 88' may be disposed along the remaining length of the. strap. In applying the strap, the portion thereof which has notches 86 is laid over theedge of p ane1 70. The endportion of the strap, which has aperture 84, protrudes beyond the edgeof panel 70 whereby the edge liner 82 may be inserted therethrough and lie flat'against the side of the panel 70. The strap is then bent over the transverse member 76 and secured thereto by nails or screws through one or more of the apertures 88. Inthis manner, the panel 70 is maintained by the hooking means. against the plumb members 72 m y. besevcred at thewe kened a eaa cupd notch merely by tearing or breaking the strap between the notches by a sideways pull or the like. Because of the extreme thinness of the straps, only a very small slit will be present between the panels at the locations of the straps 78 and 80. Under normal conditions such a narrow slit is not visible and would not need to be patched. However, patching may be accomplished, if desired, in any conventional manner. The internal ties as described above in connection with Figure 1 prevent the bulging of the panels and may be used with or without the means for holding the panels plumb as described in connection with Figure 4. When used together, the plumb members are preferably between the two panel walls on one side thereof only. Additionally, it is apparent that the plumbing means may be used with other types of upright structures which include one or more prefabricated panels.

Although the plumb members 72, 74, along with the transverse member 76 have been referred to as being composed of wood, it is to be understood that such members may also be of steel or any other desirable material. In case the transverse plumb is made of steel, the straps 73 and 80 may be tack-welded thereto with a single pass, or hooked on pegs protruded from the transverse member 76. Additionally, it is to be understood that the invention includes the feature of using no transverse member 76 whatsoever, but having the straps 78 twisted or otherwise arranged in such a manner that they will themselves form the hooking means around the plumb memher and the panel. That is, the strap instead of having an aperture 84 may be bent at right angles so as to hook the front side of the panel 70, while being twisted along its length so as to cause the other end portion thereof to be flat against the plumbing member.

it is to be understood that the straps can be placed on either the horizontal edge as shown or along the vertical edges of the panel. It is apparent then that each panel requires only two straps and, therefore, only two plumb members 72, 74 are necessary. This is to be contrasted with the four to six plumb members employed in conventional form work.

Although the edge liner 82 is illustrated as being a thin flat strap, preferably metallic, it is to be understood that the edge liners may be of any cross-sectional configuration with the corresponding configuration for aperture 84 and may be made of any desirable material.

Many other advantages and modifications of this invention will became apparent to those skilled in the art. Therefore, it is intended that the matter contained in the foregoing description and the accompanying drawings be interpreted as illustrative and not limitative, the scope of the invention being defined in the appended claims.

What is claimed is:

1. For use with an upright structure which has at least two opposing spaced apart prefabricated panels each having secured on its inner side and extending therefrom at least one loop means, the improvement comprising at least one spacer means including a rod having a head at each end thereof for abutment against the inner sides of said panels respectively adjacent a loop means for maintaining substantially no less than a given separation distance between said panels at least at their points of contact by said heads, and two catch means separable from but respectively associated with said heads, each catch means being shaped in the form of an elongated squared U with the bottom of the U including an aperture smaller than said heads and through which said rod extends between said heads thereby causing the catch means to be irremovable from said rod, the sides of each U extending substantially parallel with said rod, each of the top edges of the U of each catch means including a cutaway portion for interlock with the adjacent loop means when the bottom of said U is abutted against the inner side of its associated head, each cut-away portion then being substantially non-overlapping with said rod but having one side substantially tangent to said rod, and each of said catch means when so abutted having a toelike protrusion extending from one of the bottom sides of its U shape coextensively with the width of, and being adjacent the side of, its associated head so that the protrusions may abut the respective inner sides of said panels and then preclude any otherwise existing tendency of either catch means to rotate about the axis of its cut-away portions by any forces effectively exerted on its cut-away portions toward its associated head.

2. An upright structure comprising at least two opposed spaced apart prefabricated panels each having secured on its inner side and extending therefrom a plurality of loop means arranged in at least one row, a plurality of spacer means each including a rod having a head at each end thereof for abutment against the inner sides of said panels respectively adjacent opposing panel loop means for maintaining substantially no less than a given separation distance between said panels each spacer means further including two catch means separable from but respectively associated with said heads, each catch means being shaped in the form of an elongated squared U with the bottom of the U including an aperture smaller than the associated heads and through which said rod extends between said heads thereby causing each catch means to be irremovable from its associated rod, the sides of each U of each catch means extending substantially parallel with the associated rod, each of the top edges of the U of each catch means including a cutaway portion which, when the bottom of the U is abutted against the inner side of its associated head, is substantially non-overlapping with its associated rod but has one side substantially tangent to the associated rod, and each of said catch means when so 'abutted having a toe-like protrusion extending from one of the bottom sides of its U shape coextensively with the width of, and being adjacent the side of, its associated head so that the protrusions may abut the respective inner sides of said panels and then preclude any otherwise existing tendency of any catch means to rotate about the axis of its cutaway portions by any forces eifectively exerted on its cutaway portions toward its associated head, and two keeper rods, one for each of said panels extending through the loop means thereof and seated in the cut-away portions of each catch means associated With the head abutting that panel for maintaining substantially no more than said given separation distance between said panels.

References Cited in the file of this patent UNITED STATES PATENTS 838,844 Clayton Dec. 18, 1906 875,983 Clayton Jan. 7, 1908 1,911,626 Larzelere May 30, 1933 2,074,563 Schuettinger Mar. 23, 1937 2,133,605 Wikstrom Oct. 18, 1938 2,280,832 Ketcham Apr. 28, 1942 2,295,216 Joy Sept. 8, 1942 FOREIGN PATENTS 510,785 France Dec. 10, 1920 

